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So I bought some new P46s from Units w/ Pred. Chromiums pre installed. Swapped out my old head lights, put the new ones in, wired up the DDE, everything works perfect. I take my car for a spin about an hour later and get out to admire my work at a near by Albert sons parking lot, when lo and behold, fvcking condensation in the drive side head light.

Now some people are saying SEALING them is a good idea, wtf that makes no sense, u can't have a PERFECTLY sealed head light because there has to either be a side of the boot opened for the wires, or you have to cut a small X incision into the boot.

Ironically the passenger side has a BIGGER X incision then the driver side and there is NO condensation what so ever. I think cutting a bigger incision will do the trick, anyone tried this?

Yeah but even if I make sure the lens is sealed moisture can still get in from the back where the bulb comes in. The rubber shield / boot need an incision or to be left off on the edge. Get what I'm saying? I think the only true way to get rid of it is making it AIR TIGHT, which isn't realistic, or making a big enough incision for the air to properly vent out.

If you have condensation then that means water got in some how, whether it was when you were installing them or when you went for a drive. I don't think the headlight being air tight has anything to do with it. I know mine aren't and they never fog up, not even after driving in pouring rain.

Yeah, I will try making a bigger area for air to travel through the boot, hopefully this will clear it up. I have been digging around on the other forums (non bmw just head light condensation threads in general) and everyone is saying either air tight or drill holes. In my case i'm lucky enough to have that rubber boot so I don't have to drill

Are you sure that the rubber boot on the back is 100% secure. You can run the wires through the top of the boot and still make a perfect seal.

Yeah it was on pretty good, I doubt i can run all 4 wires (2 for bulb, 2 for DDE) and get a good seal (bulb wires are pretty thick). I'm just going to make a bigger incision tomorrow, if that doesn't work i'll look into the completely sealed options.

PS, this makes me laugh because on my halogen housing I ran the DDE wires out of the back of the light and it was NO WHERE NEAR a perfect seal, 2 months, not on hint of fogging...

try opening it up...drying out all the condensation...then stashing a couple of silica gel desiccants between the trim and the headlight casing...its worked for me and I had persistent condensation on my passenger's side headlight that was driving me totally nuts...

try opening it up...drying out all the condensation...then stashing a couple of silica gel desiccants between the trim and the headlight casing...its worked for me and I had persistent condensation on my passenger's side headlight that was driving me totally nuts...

That is a really good idea that I'm surprised noone had come up with earlier - silica packats, hell, even rice would work